Coating compositions containing low VOC compounds

ABSTRACT

Coating compositions containing coalescents and a latex polymer, wherein the coalescent has a volatile organic content of less than about 50% and is dispersible in the coating composition.

RELATED APPLICATIONS

This application is a Continuation-In-Part of U.S. patent application Ser. No. 10/081,351, filed 22 Feb. 2002, which claims the benefit of the U.S. Provisional Application No. 60/270,680, filed 22 Feb. 2001, both of which are incorporated by reference in their entireties.

BACKGROUND

Coating compositions, such as paints, that include latex polymer particles typically also include a coalescent (i.e., coalescing agent or film-forming agent) in addition to pigments and fillers. The coalescent functions as a solvent as well as a plasticizer for the polymer particles to soften the latex polymer particles and assist in the formation of a continuous coating or film after applying to a surface and allowing to dry.

Useful coalescents are generally stable in the presence of water, compatible with other ingredients typically used in paint formulations, particularly the latex polymers, such that the stability of the latex-based composition is not compromised. They are also typically sufficiently volatile to escape when the applied coating composition is allowed to dry, but sufficiently nonvolatile to evaporate more slowly than other ingredients (e.g., drying retarders, antifreezes) that delay film formation. However, there is a general desire in the industry to reduce volatile organic emissions, thereby reducing the environmental and health concerns.

Governments have established regulations setting forth guidelines relating to volatile organic compounds that may be released into the atmosphere. To reduce the level of volatile organic compounds, new high solids coating compositions have been developed as well as powder coating compositions that do not include volatile compounds, have a reduced concentration of volatile compounds, or incorporate compounds having a lower volatility. Reducing the volatility of coalescents, solvents, plasticizers, etc. can adversely affect the balance of properties needed in a latex-based coating composition, however. Thus, there is a need for coalescents, solvents, plasticizers, etc. that can be used in coating compositions, such as paints, that do not compromise stability, compatibility, film formation ability, or the desirable properties of the applied coating, etc.

SUMMARY

The present invention provides a class of compounds that have a relatively low volatile organic content. Such compounds can be used in coating compositions, preferably paints, as coalescing agents, solvents, plasticizers, etc. A suitable coalescent is dispersible in the coating composition, which is preferably stable over time. Preferably, the compound, when used as a coalescent, facilitates the formation of polymer films of the latex polymer at a temperature of less than about 25° C. (more preferably, at about 4° C. to about 10° C., and most preferably, at about 4° C. to about 5° C.). Thus, there is provided a coating composition that includes a latex polymer and a coalescent (which can also function as a solvent or a plasticizer). Such coating compositions can be coated onto a substrate and dried, as with a paint, for example.

In one embodiment, a coating composition (preferably, a paint) includes: a latex polymer; and a coalescent having the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group (preferably, having less than 100 carbon atoms); X is a divalent organic group (preferably, having 2 to 8 carbon atoms, and more preferably, 3 to 5 carbon atoms); r is 0 to 1; n is 1 to 10 (preferably, n is 1 to 5, more preferably, n is 1 to 3, and most preferably, n is 2 to 3); and R² is hydrogen or an organic group (preferably, having less than 100 carbon atoms); with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; with the proviso that the coalescent has less than two aliphatic unsaturated carbon-carbon bonds when r is zero (preferably, the coalescent does not include aliphatic unsaturated carbon-carbon bonds when r is zero, and more preferably, the coalescent does not include aliphatic unsaturated carbon-carbon bonds); wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%, more preferably, less than about 20%, and most preferably, less than about 15%) and is dispersible in the coating composition. Preferably, r is one.

In another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R² is hydrogen or an organic group; with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; with the proviso that the coalescent does not include aliphatic unsaturated carbon-carbon bonds; with the proviso that r is one when R² is H; wherein the coalescent has a volatile organic content of less than about 50%, is dispersible in the coating composition, and facilitates the formation of polymer films of the latex polymer at a temperature of less than about 25° C. (preferably, at a temperature of about 4° C. to about 10° C., and more preferably, at a temperature of about 4° C. to about 5° C.).

In another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ has the formula R³—(CH₂)_(m)—(O(CH₂)_(p))_(q)— wherein R³ is an alkyl or aryl group, m is 0 to 24, p is 1 to 4, and q is 0 to 50; X has the formula —(CH₂)_(s)—, wherein s is 2 to 8; r is 0 to 1; n is 1 to 10; and R² is hydrogen or R¹; wherein the coalescent has a volatile organic content of less than about 50%, is dispersible in the coating composition, and facilitates the formation of polymer films of the latex polymer at a temperature of less than about 25° C. (preferably, at a temperature of about 4° C. to about 10° C., and more preferably, at a temperature of about 4° C. to about 5° C.).

In yet another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X is a divalent hydrocarbyl moiety or an organic group containing nonperoxidic oxygen atoms and carbonyl groups; and n is 1 to 10; wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%) and is dispersible in the coating composition.

In still another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X has the formula —(CH₂)_(s)—, wherein s is 2 to 8; and n is 1 to 10; wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%) and is dispersible in the coating composition.

In another embodiment, a coating composition includes: a latex polymer; and a coalescent having the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing nonperoxidic oxygens; X is an organic group containing nonperoxidic oxygens and carbonyl groups; and n is 1 to 10; wherein the coalescent has a volatile organic content of less than about 50% (preferably, less than about 30%) and is dispersible in the coating composition.

The present invention also provides methods of coating that include: providing a coating composition as described herein; applying the coating composition to a substrate (e.g., wall); and allowing the coating composition to dry.

DEFINITIONS

The term “dispersible” in the context of a dispersible coalescent means that the coalescent can be mixed into the coating composition to form a uniform mixture without the use of high shear mixing.

The term “stable” in the context of a coating composition containing a dispersible coalescent means that the coalescent does not phase separate from the coating composition upon standing at 120° F. (49° C.) for four weeks.

The terms “volatile organic content” and “VOC” herein mean the volatility of the compound as measured by ASTM method D2369-90.

The term “organic group” means a hydrocarbon (i.e., hydrocarbyl) group with optional elements other than carbon and hydrogen in the chain, such as oxygen, nitrogen, sulfur, and silicon that is classified as an aliphatic group, cyclic group, or combination of aliphatic and cyclic groups (e.g., alkaryl and aralkyl groups). The term “aliphatic group” means a saturated or unsaturated linear or branched hydrocarbon group. This term is used to encompass alkyl, alkenyl, and alkynyl groups, for example. The term “alkyl group” means a saturated linear or branched hydrocarbon group including, for example, methyl, ethyl, isopropyl, t-butyl, heptyl, dodecyl, octadecyl, amyl, 2-ethylhexyl, and the like. The term “alkenyl group” means an unsaturated linear or branched hydrocarbon group with one or more carbon-carbon double bonds, such as a vinyl group. The term “alkynyl group” means an unsaturated linear or branched hydrocarbon group with one or more carbon-carbon triple bonds. The term “cyclic group” means a closed ring hydrocarbon group that is classified as an alicyclic group, aromatic group, or heterocyclic group. The term “alicyclic group” means a cyclic hydrocarbon group having properties resembling those of aliphatic groups. The term “aromatic group” or “aryl group” means a mono- or polynuclear aromatic hydrocarbon group. The term “heterocyclic group” means a closed ring hydrocarbon in which one or more of the atoms in the ring is an element other than carbon (e.g., nitrogen, oxygen, sulfur, etc.).

Substitution is anticipated on the organic groups of the coalescents used in the coating compositions of the present invention. As a means of simplifying the discussion and recitation of certain terminology used throughout this application, the terms “group” and “moiety” are used to differentiate between chemical species that allow for substitution or that may be substituted and those that do not allow or may not be so substituted. Thus, when the term “group” is used to describe a chemical substituent, the described chemical material includes the unsubstituted group and that group with O, N, Si, or S atoms, for example, in the chain (as in an alkoxy group) as well as carbonyl groups or other conventional substitution. Where the term “moiety” is used to describe a chemical compound or substituent, only an unsubstituted chemical material is intended to be included. For example, the phrase “alkyl group” is intended to include not only pure open chain saturated hydrocarbon alkyl substituents, such as methyl, ethyl, propyl, t-butyl, and the like, but also alkyl substituents bearing further substituents known in the art, such as hydroxy, alkoxy, alkylsulfonyl, halogen atoms, cyano, nitro, amino, carboxyl, etc. Thus, “alkyl group” includes ether groups, haloalkyls, nitroalkyls, carboxyalkyls, hydroxyalkyls, sulfoalkyls, etc. On the other hand, the phrase “alkyl moiety” is limited to the inclusion of only pure open chain saturated hydrocarbon alkyl substituents, such as methyl, ethyl, propyl, t-butyl, and the like. The term “hydrocarbyl moiety” refers to unsubstituted organic moieties containing only hydrogen and carbon.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is directed to coating compositions that include coalescents, which can optionally also function as plasticizers and/or solvents, and coatings prepared therefrom. Preferably, the coating compositions are in the form of paints. Preferably, such coating compositions include a polymer, preferably, a latex polymer, in addition to one or more coalescents. The coalescent is dispersible in the coating composition which is preferably stable over time (i.e., the coalescent does not phase separate from the coating composition upon standing at 49° C. for four weeks).

The coating compositions of the present invention are advantageous in that they have a relatively low volatile organic content without sacrificing the balance of properties desired for an applied (i.e., dry) coating, such as a paint. For example, the coating compositions of the present invention provide an applied coating having a preferred scrub resistance, as determined by the test set forth in the Examples Section herein below, of at least about that of TEXANOL, which is an alcohol/ester made from trimethylpentane diol and isobutyric acid ((H₃C)₂—CH—C(O)—O—CH₂—C(CH₃)₂—CH₂(OH)—CH(CH₃)₂).

Preferably, the coating compositions include a compound having a relatively low volatile organic content (VOC), and more preferably, a relatively low molecular weight. Typically, the volatile organic content, as determined by the test set forth in the Examples Section herein below, is no greater than about 50%, preferably, no greater than about 30%, more preferably, no greater than about 20%, and most preferably, no greater than about 15%, based on the original weight of the coalesent. Preferably, the number average molecular weight of such compounds is no greater than about 750, and more preferably, less than about 500.

Preferably, such compounds are good coalescents. That is, they preferably and advantageously provide good film forming properties for a latex polymer. More preferably, a particularly desirable group of compounds are those that provide good film forming properties at low temperatures (e.g., below room temperature), as determined by the test set forth in the Examples Section herein below. Preferably, such compounds facilitate the formation of polymer films of a latex polymer at a temperature of less than about 25° C. (more preferably, at a temperature of about 4° C. to about 10° C., and most preferably, at a temperature of about 4° C. to about 5° C.).

Preferably, such low VOC compounds are of the formula R¹—(C(O)—X_(r)—O)_(n)—R² wherein: n is 1 to 10; R¹ is an organic group, preferably, having less than 100 carbon atoms, and more preferably, having 3 to 24 carbon atoms; R² is hydrogen or an organic group, preferably, having less than 100 carbon atoms; and X is a divalent organic group, preferably, having 2 to 8 carbon atoms, and more preferably, 3 to 5 carbon atoms; and r is 0 to 1. Preferably, n is 1 to 5, more preferably, n is 1 to 3, and most preferably, n is 2 to 3.

Preferably, R¹ is a hydrocarbyl moiety, although for certain preferred embodiments R¹ is an organic group that includes substituents selected from the group of nonperoxidic oxygen atoms, carbonyl groups, hydroxyl groups, and combinations thereof, more preferably, substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof, and most preferably, nonperoxidic oxygen atoms. For certain embodiments, R¹ has the formula R³—(CH₂)_(m)—(O(CH₂)_(p))_(q)— wherein R³ is an alkyl or aryl group, m is 0 to 24, p is 1 to 4 (preferably, p is 1 to 2), and q is 0 to 50. In this preferred formulation for R¹, m+pq is preferably less than about 23.

Preferably, X is a divalent hydrocarbyl moiety, although for certain preferred embodiments, X is an organic group that includes substituents selected from the group of nonperoxidic oxygen atoms, carbonyl groups, and combinations thereof, and more preferably, nonperoxidic oxygen atoms and carbonyl groups. For certain emdodiments, X has the formula —(CH₂)_(s)— wherein s is 2 to 8, and preferably, s is 3 to 5.

For certain embodiments, X includes unsaturation. Preferably, X includes at least one carbon-carbon double bond. A preferred example of such a compound is bis(2-ethylhexyl)maleate (i.e., dioctyl maleate), which is available from commercial sources such as Aldrich Chemical Co., Milwaukee, Wis.

Preferably, R² is hydrogen, although for certain preferred embodiments R² is R¹ as defined above. For certain embodiments, r is one, preferably when R² is hydrogen.

For certain embodiments, R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; and R¹ and R² together (i.e., the coating composition) include less than two aliphatic unsaturated carbon-carbon bonds when r is zero, preferably, R¹ and R² together (i.e., the coating composition) do not include any aliphatic unsaturated carbon-carbon bonds when r is zero, and more preferably, R¹ and R² together (i.e., the coating composition) do not include any aliphatic unsaturated carbon-carbon bonds.

For certain embodiments, R¹ is an organic group having 3 to 24 carbon atoms and substituents selected from the group of oxygen atoms, carbonyl groups, hydroxyl groups, and combinations thereof; and R² is hydrogen.

A preferred group of such compounds have the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R² is hydrogen or an organic group; with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; with the proviso that the coalescent has less than two aliphatic unsaturated carbon-carbon bonds when r is zero. Such compounds can be made from caprolactone and an alcohol, for example.

Another preferred group of such compounds have the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R² is hydrogen or an organic group; with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; with the proviso that the coalescent does not include aliphatic unsaturated carbon-carbon bonds; with the proviso that r is one when R² is hydrogen.

Another preferred group of such compounds have the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ has the formula R³—(CH₂)_(m)—(O(CH₂)_(p))_(q)— wherein R³ is an alkyl or aryl group, m is 0 to 24, p is 1 to 4, and q is 0 to 50; X has the formula —(CH₂)_(s)—, wherein s is 2 to 8; r is 0 to 1; n is 1 to 10; and R² is hydrogen or R¹.

Another preferred group of such compounds have the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X is a divalent hydrocarbyl moiety or an organic group containing nonperoxidic oxygen atoms and carbonyl groups; and n is 1 to 10. Such compounds can be made from a glycidyl ester of neodecanoic acid (e.g. CARDURA E10) and a carboxylic acid, for example.

Another preferred group of such compounds have the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X has the formula —(CH₂)_(s)—, wherein s is 2 to 8; and n is 1 to 10.

Another preferred group of such compounds have the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing nonperoxidic oxygens; X is an organic group containing nonperoxidic oxygens and carbonyl groups; and n is 1 to 10.

These compounds can be formed using standard organic synthesis techniques, which are well known to one of skill in the art. Specific syntheses are set forth in the Examples Section herein below.

The preferred polymers of the coating compositions of the present invention include latex polymers (i.e., latices). These are well known in the paint art and are typically particles emulsified or suspended in an aqueous medium. They include, for example, the polymerization products of ethylenically unsaturated monomers, such as alkyl and alkoxy acrylates or methacrylates, vinyl esters of saturated carboxylic acids, monoolefins, conjugated dienes, optionally with one or more monomers, such as, for example, styrene, methyl methacrylate, butyl acrylate, 2-ethylhexyl acrylate, vinyl acetate, acrylonitrile, and vinyl chloride. The latex polymers can have a wide range of glass transition temperatures, depending on the desired properties of the resultant coating.

The amount of polymers and the low VOC compounds (e.g., coalescents) present in the coating compositions of the present invention include an amount that provides the desired result. Preferably, one or more relatively low VOC compounds, which preferably function as coalescents, are present in a coating composition in an amount of at least about 1 percent by weight (wt-%), more preferably, at least about 2 wt-%, and most preferably, at least about 5 wt-%, based on polymer solids. Preferably, one or more relatively low VOC compounds are present in a coating composition in an amount of no greater than about 50 wt-%, and more preferably, no greater than about 25 wt-%, based on polymer solids. When mixtures of such coalescents are used, the numerical values of the variables in the formulas described herein are averages.

Other components of the coating compositions of the present invention include those typically used in paint formulations, such as pigments, fillers, thickeners, biocides, mildewcides, surfactants, dispersants, defoamers, and the like. The coating compositions can be made using standard techniques known in the paint industry.

EXAMPLES

The following examples are offered to aid in understanding of the present invention and are not to be construed as limiting the scope thereof. Unless otherwise indicated, all parts and percentages are by weight.

VOC Testing:

Testing of coalescents were performed using ASTM method D2369-90. Approximately 0.5 gram (g) of coalescent was weighed into an aluminum weighing dish and placed in a forced air oven at 110° C. for 1 hour. The dish was then reweighed and the mass lost represents the percent (%) VOC of the coalescent.

Scrub Resistance:

The coating was drawn down on a black vinyl scrub test chart (available from the Leneta Company) with a standard 3-mil (0.0762 millimeter (mm)) Bird film applicator (available from Byk Gardner). The film was allowed to dry at room temperature for 7 days. Scrub resistance was measured with a Gardner Abrasion Tester (available from Byk Gardner) using 10 g of scrub media. The number of cycles until the coating film was first removed was recorded.

Low Temperature Coalescence (LTC):

The coating was drawn down on a Penopac paper chart (available from the Leneta Company) with a standard 3-mil Bird film applicator. The chart was then put in the refrigerator at 40° F. (4.4° C.) until dry. Coating films that did not exhibit any cracking were determined to pass. Any cracking of the film was considered a failure.

Example 1 Preparation of Coalescent Compounds

Run 1. Preparation of Coalescent

Epsilon-caprolactone (2-oxepanone) (174 g), 1-dodecanol (173 g), and FASCAT 2003 (stannous octoate, available from Atofina Chemicals) (0.2 g) were charged to a 4-neck 500-mL round bottom flask fitted with mechanical stirring. The contents of the flask was heated to 150° C. and held until the free caprolactone level was below 0.5% as measured by GC (approximately four hours), then cooled to room temperature.

Runs 2-20. Preparation of Coalescents

A variety of coalescents were prepared following the procedure of Example 1, Run 1, with the exception that the 174 g caprolactone was varied according to the amount listed in Table 1A, and the 173 g of 1-dodecanol used in Example 1, Run 1 was replaced with the alcohol and amount listed in Table 1A. TABLE 1A caprolactone Molar Ratio (grams)/ Caprolactone: Run Alcohol alcohol(grams) Alcohol % VOC 1 1-dodecanol 174/173 1.64:1  7.0% 2 1-dodecanol 200/163   2:1 6.0% 3 1-dodecanol 225/147 2.5:1 4.0% 4 1-dodecanol   240/130.5   3:1 3.0% 5 1-dodecanol 265/108   4:1 2.0% 6 benzyl alcohol 228/108   2:1 9.0% 7 2,2,4-trimethyl-1,3- 196/140 1.7:1  15% pentane diol (TMPD) 8 2-ethylhexanol, 2 mol 157/200 1.5:1  10% EO 9 2-amino-2-methyl-1-  228/71.2 2.5:1 3.0% propanol (AMP-95) 10 1-hexanol  228/81.8 2.5:1 5.0% 11 2-butoxyethanol (butyl  228/94.4 2.5:1 8.0% cellosolve) 12 1-butanol  228/74.1 2.5:1 7.0% 13 2(2-butoxyethoxy)   228/129.8 2.5:1 9.0% ethanol (butyl carbitol) 14 1-octanol   228/104.2 2.5:1 5.0% 15 2-propxyethanol  228/83.2 2.5:1 9.0% (propyl cellosolve) 16 1-propanol 228/48  2.5:1 11.0%  17 2-butyl-2ethyl-1,3 174/98  2.5:1 3.5% propanediol 18 1,3-butanediol 228/72  2.5:1 3.0% 19 2-methoxyethanol  228/60.8 2.5:1 7.0% (methyl cellosolve) 20 2-ethoxyethanol  228/72.1 2.5:1 7.5% (cellosolve) *TEXANOL is 99.5% VOC by this method

Example 2 Preparation of Coalescent Compounds

Run 1. Preparation of Coalescent from CARDURA E10

CARDURA E10 (glycidyl ester of neodecanoic acid, available from Shell Chemical) (228 g) was charged to a 4-neck 500-mL round bottom flask equipped with mechanical stirring. The flask was heated to 140° C. and 88 g isobutyric acid was fed into the flask over 90 minutes. The contents of the flask were held at 140° C. for 2 hours and cooled to room temperature.

Runs 2-3. Preparation of Coalescents

A variety of coalescents were prepared following the procedure of Example 2, Run 1, with the exception that the 88 g of isobutyric acid used in Example 2, Run 1 was replaced with the acid listed in Table 2A. TABLE 2A Amount Run Acid (Grams) % VOC 1 Isobutyric acid 88 7.0% 2 Acetic acid 60 9.0% 3 Propionic acid 74 10.0%

Example 3 Preparation of Coating Compositions

Various coating compositions were prepared by mixing the ingredients listed in Table 3A. For each composition the coalescent is as described in Examples 1 and 2. TABLE 3A Material Description Grams Water 62.0 Ethylene glycol 35.0 AMP-95 Amine, Angus 1.0 TAMOL 731 Dispersant, Rohm&Haas 10.0 DEHYDRAN 1620 Defoamer, Cognis 1.0 RCL-535 TiO₂, Millennium 245.0 KATHON LX 1.5% Biocide, Rohm&Haas 1.7 Emulsion polymer 453 Ammonium 2.0 hydroxide Coalescent 26.3 Ethylene glycol 20.9 SURFYNOL 504 Surfactant, Air Products 1.0 ACRYSOL RM- Thickener, Rohm&Haas 4.0 2020NPR ACRYSOL RM-6 Thickener, Rohm&Haas 31.0 FOAMASTER SA-3 Defoamer, Cognis 3.5 Water 156.0

TABLE 3B Example Molar Ratio Scrub 1, Caprolactone: (relative to Run Alcohol Alcohol TEXANOL) LTC 1 1-dodecanol 1.7:1 1.27 Pass 2 1-dodecanol   2:1 1.09 Pass 3 1-dodecanol 2.5:1 Pass 4 1-dodecanol   3:1 1.07 Pass 5 1-dodecanol   4:1 0.71 Pass 6 Benzyl alcohol   2:1 Pass 7 2,2,4-Trimethyl- 1.7:1 0.81 Pass 1,3-pentane diol (TMPD) 8 2-ethylhexanol, 2 mol 1.5:1 0.96 Pass EO 9 2-amino-2- 2.5:1 Fail methyl-1- propanol (AMP- 95) 10 1-hexanol 2.5:1 1.10 Pass 11 2-butoxyethanol 2.5:1 1.35 Pass (butyl cellosolve) 12 1-butanol 2.5:1 1.27 Pass 13 2(2- 2.5:1 Pass butoxyethoxy)ethanol (butyl carbitol) 14 1-octanol 2.5:1 Pass 15 2-propxyethanol 2.5:1 Pass (propyl cellosolve) 16 1-propanol 2.5:1 Pass 17 2-butyl-2ethyl-1,3 2.5:1 Pass propanediol 18 1,3-butanediol 2.5:1 Fail 19 2-methoxyethanol 2.5:1 Pass (methyl cellosolve) 20 2-ethoxyethanol 2.5:1 Pass (cellosolve) TEXANOL LTC: Pass, Scrub = 1.0

TABLE 3C Example 2, Run Acid LTC 1 Isobutyric acid Pass 2 Acetic acid Pass 3 Propionic acid Pass

TABLE 3D Example 3, Compound VOC LTC Isodecyl benzoate  15% Pass Bis(2-ethylhexyl) 0.6% Pass adipate Bis(2-ethylhexyl)   3% Pass maleate

Having thus described the preferred embodiments of the present invention, those skilled in the art will readily appreciate that the teachings found herein may be applied to yet other embodiments within the scope of the claims hereto attached. The complete disclosure of all patents, patent documents, and publications are incorporated herein by reference as if individually incorporated. 

1. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent has the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R² is hydrogen or an organic group; with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; with the proviso that the at least one coalescent has less than two aliphatic unsaturated carbon-carbon bonds when r is zero; wherein the one or more coalescents have an average combined volatile organic content of less than about 50% and are dispersible in the coating composition.
 2. The coating composition of claim 1, wherein the one or more coalescents do not phase separate from the coating composition upon standing at 49° C. for four weeks.
 3. The coating composition of claim 1, wherein the coating composition comprises a sufficient amount of the one or more coalescents to facilitate coalescence of the latex polymer.
 4. The coating composition of claim 3, wherein the one or more coalescents are present in a sufficient amount to facilitate the formation of a polymer film of the latex polymer at a temperature of less than about 25° C.
 5. The coating composition of claim 4, wherein the one or more coalescents are present in a sufficient amount to facilitate the formation of a polymer film of the latex polymer at a temperature of about 4° C. to about 10° C.
 6. The coating composition of claim 5, wherein the one or more coalescents are present in a sufficient amount to facilitate the formation of a polymer film of the latex polymer at a temperature of about 4° C. to about 5° C.
 7. The coating composition of claim 1, wherein the one or more coalescents have an average combined volatile organic content of less than about 30%.
 8. The coating composition of claim 7, wherein the one or more coalescents have an average combined volatile organic content of less than about 20%.
 9. The coating composition of claim 8, wherein the one or more coalescents have an average combined volatile organic content of less than about 15%.
 10. The coating composition of claim 1 comprising at least 1 wt-% of the at least one coalescent having the formula R¹—(C(O)—X_(r)—O)_(n)—R² based on the polymer solids of the coating composition.
 11. The coating composition of claim 10, wherein: R¹ is an organic group having 3 to 24 carbon atoms; X is a divalent organic group having 3 to 5 carbon atoms; r is 1; n is 1; R² is an organic group having less than 100 carbon atoms; and the coalescent has a number average molecular weight of less than about
 500. 12. The coating composition of claim 1 comprising at least 2 wt-% of the at least one coalescent having the formula R¹—(C(O)—X_(r)—O)_(n)—R² based on the polymer solids of the coating composition
 13. The coating composition of claim 12 comprising between 5 wt-% and 25 wt-% of the at least one coalescent having the formula R¹—(C(O)—X_(r)—O)_(n)—R² based on the polymer solids of the coating composition.
 14. The coating composition of claim 1, which is in the form of a paint.
 15. The coating composition of claim 1, wherein n is 1 to
 5. 16. The coating composition of claim 1, wherein R¹ is an organic group having less than 100 carbon atoms.
 17. The coating composition of claim 1, wherein R¹ is an organic group having substituents selected from the group of oxygen atoms, carbonyl groups, hydroxyl groups, and combinations thereof.
 18. The coating composition of claim 17, wherein R¹ is an organic group having 3 to 24 carbon atoms and substituents selected from the group of oxygen atoms, carbonyl groups, hydroxyl groups, and combinations thereof; and wherein R² is hydrogen.
 19. The coating composition of claim 1, wherein R¹ has the formula R³—(CH₂)_(m)—(O(CH₂)_(p))_(q)— wherein R³ is an alkyl or aryl group, m is 0 to 24, p is 1 to 4, and q is 0 to
 50. 20. The coating composition of claim 19, wherein p is 1 to
 2. 21. The coating composition of claim 19, wherein m+pq is less than about
 23. 22. The coating composition of claim 1, wherein R² is hydrogen or an organic group having less than 100 carbon atoms.
 23. The coating composition of claim 1, wherein X is a divalent organic group having 2 to 8 carbon atoms.
 24. The coating composition of claim 1, wherein X is an organic group having substituents selected from the group of oxygen atoms, carbonyl groups, and combinations thereof.
 25. The coating composition of claim 1, wherein X has the formula —(CH₂)_(s)—, wherein s is 2 to
 8. 26. The coating composition of claim 1, which is in the form of a paint having one or more additives selected from the group consisting of pigments, fillers, thickeners, biocides, mildewcides, surfactants, dispersants, and defoamers.
 27. The coating composition of claim 1, wherein the latex polymer comprises the polymerization product of ethylenically unsaturated monomers selected from the group consisting of: alkyl acrylates, alkoxy acrylates alkyl methacrylates, alkoxy methacrylates, vinyl esters of saturated carboxylic acids, monoolefins, conjugated dienes, and vinyl chloride.
 28. The coating composition of claim 1, wherein X includes at least one carbon-carbon double bond.
 29. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent is bis(2-ethylhexyl)maleate.
 30. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent has the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R² is hydrogen or an organic group; with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(n)— wherein s is 2 to 8; with the proviso that the at least one coalescent has less than two aliphatic unsaturated carbon-carbon bonds when r is zero; wherein the coalescent has at least 17 carbon atoms or at least 15 carbon atoms and at least one hydroxyl group; wherein the coalescent has a number average molecular weight of no greater than about 750; and wherein the one or more coalescents have an average combined volatile organic content of less than about 50% and are dispersible in the coating composition.
 31. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent is present in a quantity of at least 1 wt-% based on the polymer solids of the coating composition and has the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ is an organic group; X is a divalent organic group; r is 0 to 1; n is 1 to 10; and R² is hydrogen or an organic group; with the proviso that R¹ includes at least three carbon atoms when X is not —(CH₂)_(s)— wherein s is 2 to 8; with the proviso that the at least one coalescent does not includes aliphatic unsaturated carbon-carbon bonds; with the proviso that r is one when R² is hydrogen; wherein the one or more coalescents have an average combined volatile organic content of less than about 50%, are dispersible in the coating composition, and facilitate the formation of a polymer film of the latex polymer at a temperature of less than about 25° C.
 32. The coating composition of claim 31, wherein the one or more coalescents are present in a sufficient amount to facilitate the formation of a polymer film of the latex polymer at a temperature of about 4° C. to about 10° C.
 33. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent is present in a quantity of at least 1 wt-% based on the polymer solids of the coating composition and has the formula: R¹—(C(O)—X_(r)—O)_(n)—R² wherein: R¹ has the formula R³—(CH₂)_(m)—(O(CH₂)_(p))_(q)— wherein R³ is an alkyl or aryl group, m is 0 to 24, p is 1 to 4, and q is 0 to 50; X has the formula —(CH₂)_(s)—, wherein s is 2 to 8; r is 0 to 1; n is 1 to 10; and R² is hydrogen or R¹; wherein the one or more coalescents have an average combined volatile organic content of less than about 50%, are dispersible in the coating composition, and facilitate the formation of a polymer film of the latex polymer at a temperature of less than about 25° C.
 34. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent is present in a quantity of at least 1 wt-% based on the polymer solids of the coating composition and has the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X is a divalent hydrocarbyl moiety or an organic group containing nonperoxidic oxygen atoms and carbonyl groups; and n is 1 to 10; wherein the one or more coalescents have an average combined volatile organic content of less than about 50% and are dispersible in the coating composition.
 35. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent is present in a quantity of at least 1 wt-% based on the polymer solids of the coating composition and has the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing substituents selected from the group of nonperoxidic oxygen atoms, hydroxyl groups, and combinations thereof; X has the formula —(CH₂)_(s)—, wherein s is 2 to 8; and n is 1 to 10; wherein the one or more coalescents have an average combined volatile organic content of less than about 50% and are dispersible in the coating composition.
 36. A coating composition, comprising: a latex polymer; and one or more coalescents, wherein at least one coalescent is present in a quantity of at least 1 wt-% based on the polymer solids of the coating composition and has the formula: R¹—(C(O)—X—O)_(n)—H wherein: R¹ is a hydrocarbyl moiety or an organic group containing nonperoxidic oxygens; X is an organic group containing nonperoxidic oxygens and carbonyl groups; and n is 1 to 10; wherein the one or more coalescents have an average combined volatile organic content of less than about 50% and are dispersible in the coating composition. 